Fastener for installation tool for roof truss framing and construction system

ABSTRACT

An installation tool fastener is particularly adapted for fastening a top plate to a roof support member and other structural connections and is particularly adapted for use with an installation tool. The installation tool fastener has a head with a maximum head diameter and a recess for coupling with a drive coupler. The shank of the head has an unthreaded portion and a uniform thread which has a major diameter approximately equal to the maximum diameter of the head. The head preferably has a slight taper. The thread preferably has a 7.5 thread per inch pitch and a thread angle from approximately 25° to 45°. In one embodiment for a 6 inch fastener, the thread length is approximately 5 inches and extends along the tapered distal tip.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 14/211,685 filed on Mar. 14, 2014, whichapplication claims the priority of U.S. Provisional Patent ApplicationNo. 61/787,170 filed on Mar. 15, 2013 and U.S. Provisional PatentApplication No. 61/890,905 filed on Oct. 15, 2013, the disclosures ofwhich applications are incorporated herein in their entirety.

BACKGROUND

The present disclosure relates to generally fastening systems employedto connect wood structural members to comply with construction codes.The present disclosure relates generally to tools and methods forinstalling a fastener to secure wood framing components. Moreparticularly, this disclosure relates to tools and techniques toprecisely install fasteners to secure the top plate to roof trusses orrafters.

Local and state building codes, which are typically based on universalcodes such as the International Residential Code and the InternationalBuilding Code, set forth various requirements for securing woodenframing components. Provisions are made in such codes to require thatthe top plate and the rafters, or roof trusses, must be connected tocomply with pre-established connection force standards calculated toresist substantial uplift forces that may be experienced throughout thelifetime of the structure. For locations which are susceptible to highwind uplift and/or seismic activity, typically, a strongerforce-resistant connection between the top plate and rafters or trussesis required.

To satisfy building code requirements, the use of metal brackets and alarge number of nails are commonly installed using pneumatic nail guns.Many of the structural locations requiring these robust connections areat the top corners of walls and where walls meet roof trusses and thelike. These locations typically require workers to stand on ladders andemploy a hammer or pneumatic nail guns to nail brackets to roof rafters,roof trusses and the like. A common complaint is that the ladders arenot a stable platform and maneuvering bulky nail guns into crampedlocations while standing on a ladder is both difficult and dangerous.

The concept of a continuous load path (CLP) from the peak of the roof tothe foundation is one that is gaining some popularity in theconstruction industry. Various devices of straps, brackets, cables,threaded rods and bolts are currently employed to tie various buildingcomponents together and create an integrated unit where stress on anyone structural component is transferred to other components foradditional durability.

There are a number of techniques, fasteners and hardware items that areconventionally employed to provide the required connection between thetop plate and the rafters or roof trusses. Hurricane clips or otherforms of metal straps or clips are traditionally used and secured bymultiple nails or threaded fasteners. There is commonly a trade-offbetween connection integrity and construction efficiency. For example,hurricane clips, which are effective and widely used in many locations,may require eight or more nails or threaded fasteners to meet therequisite code connection standard.

It is possible to employ threaded fasteners such as elongated screws toreplace some of the metal brackets and nails currently employed to meetbuilding codes. However, such screws need to be installed at aparticular angle and position to ensure penetration through several woodmembers to engage, for example, a roof truss or rafter. There is a needfor a construction system that would facilitate the use of threadedfasteners to connect building components in a manner that meets buildingcodes and allows building inspectors to visually confirm correctinstallation of such threaded fasteners.

A highly secure and efficient connection between the top plate andrafters or roof trusses can be implemented by employing multiplespecialty six-inch threaded fasteners, such as TimberLOK® wood screwsmanufactured and marketed by OMG, Inc., of Agawam, Mass. To secure theframing components with the sufficient retentive force, each threadedfastener is driven through the top plate and into the rafters or rooftrusses at a 22.5±5° optimum angle with respect to the vertical.Although securing multiple threaded fasteners is typically moreefficient than attaching a hurricane clip or other strap-type connector,it is difficult to consistently implement a 22.5° angle within areasonable range of precision. The usage of protractors, levels andother similar-type tools to obtain the optimum angle for the threadedfastener has proven to be clumsy, difficult, time consuming and, atbest, only marginally advantageous over more conventional securementmethods.

The present disclosure addresses the need for a tool and method andassociated fastener to connect the top plate and rafters or roof trussesby efficiently installing multiple threaded fasteners having aconsistently precise optimum connection angle.

DEFINITIONS

As used herein, the term “roof support member” means any framingcomponent that provides structural support to a roof of a building, suchas a rafter, a truss or a horizontal ceiling joist.

As used herein, the term “top plate” means the horizontal framingcomponent (which may include two or more members such as two 2×4-inchmembers) attached to the topmost portion of the vertical structuralmembers or studs to which the roof support members are mounted andsecured.

SUMMARY

Briefly stated, an installation tool is employed to fasten a firstmember to a second member. The installation tool comprises a driverassembly having an elongated tube assembly with a proximal end and adistal end. The tube assembly is preferably telescopic. A driver, whichgenerates torque, is mounted adjacent the proximal end. A torquetransfer unit is disposed in the tube for transferring torque producedby the driver to a fastener coupler adjacent the distal end. A guideassembly is mounted adjacent the distal end and has an end and alocating surface and a fastener channel defining an axis disposed at anangle θ to the locating surface. The fastener channel is configured toreceive a fastener so that when the locating surface is engaged againstthe first member and the locating end is positioned adjacent the secondmember and the fastener is received in the channel and the driver isenergized, the fastener coupler engages the fastener and is torqued todrive the fastener through the first member at the angle θ into thesecond member. The angle θ is preferably approximately 22½°. Astabilizing piercing edge preferably projects from the locating end. Thestabilizing edge is the vertex of a square stabilizer plate.

The telescopic tube assembly comprises a proximate tube receiving thedriver and is retractable relative to a second tube. The second tube islockable to the proximal tube at an extended position. A handle isslidably adjustable relative to the telescopic tube assembly. The handlehas a grip which generally projects radially relative to the telescopictube assembly. The driver may be a battery powered drill or have a cordfor an electrical connection. The telescopic tube assembly is preferablyconfigured so that the first tube is attached to the driver and isslidably engageable with the second tube, and the first tube retractsrelative to the second tube as the driver drives the fastener. The firstmember is preferably a top plate and the second member is a roof supportmember.

An installation tool fastens a top plate to a roof support member andcomprises an elongated telescopic tube assembly with a proximal endportion and a distal end. The proximal end portion is adapted to receivea power tool. A torque transfer unit is disposed in the tube assemblyfor transferring torque produced by the power tool to a fastener coupledadjacent the distal end. A guide assembly is mounted at the distal endand has a locating end and a locating surface. A fastener channeldefines an axis disposed at an angle θ to the locating surface and isconfigured to receive a fastener. The locating surface and the end arepositioned relative to the top plate and roof support member. Thefastener is received in the channel and the received tool is energized.The fastener coupler engages the fastener and is torqued to drive thefastener through the top plate at an angle θ into the roof supportmember.

The angle θ is preferably 22½°. A handle is mounted to the telescopictube assembly. A stabilizing edge projects from the locating end. Thestabilizing edge is a vertex of a plate removably mounted to the guideassembly. The fastener is preferably a wood screw approximately 6 inchesor more in length.

A handle assembly secures the telescopic tube assembly in an extendedposition and is releasable to allow the telescopic tube assembly toretract. The tube assembly retracts a distance approximately equal tothe length of the fastener when the fastener is driven.

A method for connecting a top plate to a roof support member comprisesloading a fastener in a rotary drive installation tool havingperpendicular locating surface and locating end and employing thelocating structures to orient the fastener to be driven at a properentry angle. The method further comprises energizing the installationtool to drive the fastener through the top plate into the support memberat the proper entry angle. An end projection of the installation tool isstabbed into a wood member to stabilize the tool. The method furthercomprises seating the fastener in the top plate at a location at leastthree feet above the height of the installer while the installer remainsstanding at a ground level.

A fastener for an installation tool comprises a head portion defining arecess for coupling with a driving tool. The head portion has a maximumhead diameter. An elongated shank longitudinally extends from the headportion and terminates in a tapered tip. A helical thread longitudinallyextends along the shank and has a major diameter substantially equal tothe maximum head diameter.

In one preferred embodiment, the fastener has a longitudinal length ofapproximately 6.00 inches and the helical thread has a pitch of 7.5threads per inch. The helical thread preferably extends onto the taperedtip. The shank has an unthreaded portion adjacent the head. The majordiameter of the thread and the maximum head diameter are eachapproximately 0.26 inches in one preferred embodiment. The helicalthread extends approximately 5.00 inches. The head portion has a slighttaper from a maximum diameter portion adjacent an engagement end. In onepreferred embodiment, the recess is a T-25 AutoSert™ drive socket.

A fastener for an installation tool comprises a head portion defining arecess for coupling with a driving tool and having a first coupling endwith a maximum head diameter and uniformly tapering toward a second endat an acute angle. An elongated shank longitudinally extends from thehead portion and terminates in a tapered tip. The shank has a threadedportion and an unthreaded portion adjacent the second head end. Ahelical thread longitudinally extends along the shank onto the taperedtip and has a major diameter substantially equal to the maximum headdiameter. In one preferred embodiment, the acute angle is approximately4°.

An installation tool and fastener for fastening a member to a secondmember comprises a fastener having a head with a coupling recess and amaximum diameter and a shank extending from the head and having a threadwith an uninterrupted major diameter substantially equal to the maximumhead diameter. A transfer assembly comprises an elongated telescopictube assembly having a proximal end portion and a distal end. Theproximal end portion is adapted to receive a power tool. A torquetransfer unit is disposed in the tube assembly for transferring torqueproduced by the power tool to a fastener coupler adjacent the distalend. A guide assembly is mounted at the distal end and has a guide and afastener channel defining an axis and a uniform channel diameter. Thechannel diameter is slightly greater than the major diameter of thefastener thread and is configured to receive the fastener. When theguide is positioned relative to the first member, the fastener isreceived in the channel and the received tool is energized, the fastenercoupler extends into the head recess to rotatably engage the fastenerand the received tool drives the fastener through the first member intothe second member.

In one embodiment, the fastener is a wood screw approximately 6.00inches or more in length and the maximum head diameter and the majordiameter of the fastener thread is approximately 0.26 inches. The headpreferably extends an axial length of 0.20 inches and has a uniforminward taper at an acute angle from the maximum head diameter. Thefastener thread preferably has pitch of 7.5 threads per inch and athread flank angle having a range of 25° to 45°.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, partly broken away, of a fastener installationtool for securing a top plate to a roof support member;

FIG. 2 is a fragmentary top plan view of the installation tool of FIG.1;

FIG. 3 is a fragmentary partially disassembled side view of theinstallation tool of FIG. 1;

FIG. 4 is a representative perspective view, partly in schematic, of astructure during its construction phase and illustrating the usage of afastener to connect a top plate to a roof support member;

FIG. 4A is a fragmentary side sectional view of the structure of FIG. 4,illustrating a fastener connecting a top plate to a roof support memberat a location adjacent a vertical stud;

FIG. 4B is a fragmentary side sectional view of the structure of FIG. 4,illustrating a fastener connecting a top plate to a roof support memberat a location between vertical studs;

FIG. 5 is a side elevational view, portions broken away to show detailand partly in diagram form, of the installation tool of FIG. 1;

FIG. 6 is a side elevational view, portions broken away to show detailand partly in diagram form, of a modified embodiment of the fastenerinstallation tool of FIG. 1;

FIG. 7 is a perspective view, partly in diagram form, of a guide portionof the installation tool of FIG. 1;

FIG. 8 is a perspective view of the guide portion of FIG. 7, portionsbeing shown in phantom and portions being shown to reveal internaldetail;

FIG. 9 is an annotated composite schematic view illustrating thesequential operation of the installation tool of FIG. 1;

FIG. 10 is a side elevational view, partly broken away, of a secondembodiment of a fastener installation tool for connecting a top platewith a roof support member;

FIG. 11 is a fragmentary top plan view of the installation tool of FIG.10;

FIGS. 12A-12C are side elevational views, partly in schematic,illustrating the sequential operation of the installation tool of FIG.10;

FIG. 13 is a side elevational view, partly broken away, of a thirdembodiment of a fastener installation tool for connecting a top platewith a roof support member;

FIG. 14 is a fragmentary top plan view of the installation tool of FIG.13;

FIGS. 15A-15D are annotated representative side elevational views,partly in schematic, illustrating the sequential operation of theinstallation tool of FIG. 13;

FIGS. 16A-16B are schematic diagrams illustrating the usage andversatility of a representative fastener installation tool for differentstructural heights and wherein the installers have different heights;

FIG. 17 is a perspective view of a fourth embodiment of an installationtool without the power driver assembly wherein certain external portionsare shown as transparent to reveal internal components;

FIG. 18 is an enlarged perspective view of a portion of the installationtool of FIG. 17 wherein certain external components are shown astransparent to reveal internal components;

FIGS. 19A and 19B are top sectional views of portions of theinstallation tool of FIG. 17;

FIG. 20 is an enlarged end sectional view of the installation tool ofFIG. 17 and further illustrating a fastener received in the installationtool;

FIG. 21 is an enlarged generally top plan view of the guide head portionof the installation tool of FIG. 17;

FIG. 22 is an enlarged generally bottom perspective view of a guide headportion of FIG. 21;

FIG. 23 is an enlarged generally opposite side elevational view,portions removed, of a handle assembly for the installation tool of FIG.17;

FIG. 24 is an enlarged side elevational view, portions in section andportions removed, of the handle assembly of FIG. 23;

FIG. 25 is an enlarged generally right side view of a portion of thehandle portion of FIG. 24, taken from the right thereof and partiallybroken away to show detail

FIG. 26 is an annotated side elevational view, partly in schematic, ofan installation tool;

FIG. 27 is a side elevational view, partly in schematic and partlyannotated, of an installation tool;

FIGS. 28A and 28B are annotated side views of an installation tooltogether with an enlarged top plan view of a portion of the tool,respectively;

FIG. 29 is an annotated side elevational view of an installation tool;

FIG. 30 is a schematic view of an installer illustrating a belt holsterand a representative installation tool for reception by said holster;

FIGS. 31A and 31B are respectively a schematic view illustrating abandolier holder for fasteners and a representative installation tooland an enlarged fragmentary front view of the bandolier holder andfasteners;

FIGS. 32A and 32B are respectively a schematic side view of athigh-mounted fastener holder and a representative installation tool andan enlarged fragmentary front view of the thigh-mounted fastener holderand fasteners;

FIG. 33 is a perspective view of a representative fastener that may beemployed in the installation tools;

FIGS. 34A-34D are respectively a side view of a fastener employed in aninstallation tool, an enlarged top plan view of the fastener and a sideelevational view of a fastener with a different tint together with anenlarged top plan view of the fastener with the different tint;

FIGS. 35A-35E schematically illustrate an installer using aninstallation tool for fastening respectively a truss to a top plate, astud to a top plate, a stud to a bottom plate, a bottom plate to a rim,and a top plate to a rim;

FIGS. 36A-36C are respectively a perspective view, a diagrammatic sideview and an end view of a fastener which may be employed for aninstallation tool;

FIGS. 37A-37C are respectively a diagrammatic view of a fastener whichmay be employed for an installation tool, a perspective view of thefastener and a top plan view of the head of the fastener;

FIGS. 38A-38C are respectively fragmentary portions of a perspectiveview of a representative construction illustrating the use of a bracketassembly, an exploded view of the brackets, and a side sectional viewillustrating the mounting of the brackets;

FIGS. 39A-39E respectively illustrate another bracket for constructionin connection with a portion of a truss, a schematic view of a fastenerin connection with a second truss assembly portion together with thebrackets, a third side end view of the bracket together with a fastenerin a truss assembly, a perspective view of the bracket and a sideelevational view of the bracket;

FIGS. 40A-40B respectively illustrate a perspective view of anotherbracket as mounted in place and a top view in a preassembled stage forthe bracket;

FIGS. 41A-41D respectively illustrate a first step and tool which may beemployed in installing the bracket of FIGS. 40A and 40B, a second stepin the installation process, a third step in the installation process,and an installed view of the bracket;

FIG. 42 is a representative perspective view of a structure during itsconstructive phase and illustrating another embodiment of aninstallation tool guide head;

FIG. 43 is a representative perspective view, partly in schematic, of astructure during its construction phase and illustrating a furtherembodiment of an installation tool guide head; and

FIGS. 44A-F are respectively a side view; a left side end view; adiagrammatic sectional view taken along line C-C of FIG. 44B; anenlarged diagrammatic sectional view of the circled portion of FIG. 44A;an enlarged fragmentary sectional view, partly in diagram form, of thesectional view of FIG. 44C; and an enlarged fragmentary diagrammaticview of a thread portion, of a fastener which may be employed with aninstallation tool.

DETAILED DESCRIPTION

With reference to the drawings wherein like numerals represent likeparts throughout the several figures, a fastener installation tool isgenerally designated by the numeral 10. The fastener installation tool10 is a heavy-duty hand tool adapted for installing threaded fasteners12 at a consistent angle of approximately 22½° (to the vertical) into atop plate for connection with a roof support member.

As best illustrated in FIGS. 4, 4A and 4B, for a representativestructure 20 for which the installation tool 10 is particularly adapted,a top plate 22, which may include a single 2×4 or a double 2×4, ismounted at the top of spaced vertical studs 24. Roof support members 26of roof trusses 28 are mounted and supported on the top plate 22.Threaded fasteners 12 are driven into the top plate at a 22½° angle forengagement with the roof support member 26. Multiple spaced threadedfasteners 12 are sequentially driven at pre-established spacings toprovide the proper uplift resistance.

FIG. 4A illustrates the fastener driven at the upper location of thestud 24. FIG. 4B illustrates the fastener as driven at the locationalong the top plate between the vertical studs 24. The fasteners 12 areeach preferably a six-inch fastener having a continuous threaded portionwith a pointed tip and a head defining a socket or a six-inch TimberLOK®fastener manufactured and marketed by OMG, Inc., of Agawam, Mass. TheTimberLOK® fastener 12 has a hex head 14 and a drill tip 16. Alternativeconfigurations for head 14 are also possible.

As will be further described below, the installation tool 10 ispreferably dimensioned, principally by means of the length of atelescopic tube assembly 30, to provide an installation tool which maybe effectively used by installers having a wide range of height andreach for a wide range of commonly vertically dimensioned structures.The principal function of the telescopic tube assembly 30 is to exertpositive forward or upward pressure against the top plate/roof supportinterface.

With reference to FIGS. 5 and 6, representative tube assembly lengthsare designated by L and l and representative fastener lengths aredesignated by D and d which also represents the travel distance to drivethe screws. For one example in FIG. 5, L=36.14″ and D=8″. In FIG. 6,l=27.4″ and d=6″. The telescopic tube assembly 30 preferably has amaximum length of between 27.4 inches and 36.14 inches to accommodatethe height and reach of the installer. For a six-inch fastener 12, thetelescopic assembly 30 must retract 6 inches to drive the fastener, aswill be described below.

The installation tool 10 dimensions allow for the tool to be effectivelyand efficiently used for connecting the top plates 22 to the roofsupport members 26 without requiring the use of a ladder, platforms orother means for providing the proper effective height relationship fordriving the fasteners 12. Moreover, the proper fastener angle may besequentially implemented from location to location along the top plate22 to ensure a proper consistent angle for each of the multiplefasteners and to provide an integrated composite connection having anuplift resistance of high integrity.

The installation tool 10 preferably comprises a driver assembly 40 whichincludes a power driver 42. The driver 42 may be a conventional drillgun such as DeWalt™ model or an impact driver. The elongated telescopictube assembly 30, which may have a rounded, rectangular or otherprofile, is mounted over and attaches to the forward torque end 44 ofthe driver 42. The telescopic tube assembly 30 comprises a proximal tube32 which receives and mounts the driver 42 and a longer tube 34 securedto the tube 32. During fastener driving, tube 32 slides relative to tube34 which essentially remains stationary in relation to the components tobe connected by the fastener. Tube 34 terminates in a distal end 36.

A fastener guide assembly 50 is mounted at the distal tip 36 of the tubeassembly. The guide assembly 50 provides the proper alignment structurefor implementing the preferred 22½° entry angle for the fastener. Theassembly 50 also engages the support member for stabilizing theinstallation tool during the driving process. The guide assembly 50 isdimensioned in accordance with the dimensions of a given fastener. Theguide assembly has a fastener channel 52 which functions to receive andload the fastener in a muzzle-loading fashion. The fastener drill tip 16is positioned proximate the channel opening 53. The fastener is insertedhead 14 first into the fastener channel 52 of the guide assembly. Thefastener head 14 is engaged by a complementary torque coupler 43, suchas a socket, for a hex thread fastener or a projecting coupler for afastening head socket at the applicator end of the torque drive assemblytrain 45. The drive train 45, which may include multiple components,extends through and is housed within the tube assembly 30 and is drivenby the torque driver 42.

With reference to FIGS. 7 and 8, guide assembly 50 is preferably a castor molded member of a lightweight rigid form which is mounted at thedistal end 36 of the tube assembly. The guide assembly 50 has a frame 60with a planar locating or engagement surface 62 disposed at an acuteangle with respect to lower planar mounting surface 64. Mounting surface64 preferably engages against the end of the tube assembly andtransversely extends across the end of the tube 34. A planar end plate66 is preferably perpendicular to surface 62 and is positioned andconfigured to closely approach or even contact the underside of the roofsupport member 26 (as will be explained below). The acute angle ispreferably 22½°, although other angles may be provided depending on theintended application of the installation tool 10.

The fastener channel 52, which may be formed by a cylinder, has acentral axis which is perpendicular to the surface 64. The fastenerchannel axis is disposed at an acute angle of preferably 22½° to thesurface 62. Surface 62 defines the channel opening 53. The channel 52receives the fastener 12 so that the head 14 is proximate and readilyengageable with the torque coupler 43.

A transverse slot 65 receives an alignment bracket 68 having a T-shapedsection which protrudes transversely at opposed sides of the engagementsurface 62 and also projects outwardly from the surface 62. Thealignment bracket 68 is positioned and configured to fit or ride belowthe 2×4 of the top plate 22 to ensure proper perpendicular alignmentwith the top plate 22. The alignment bracket 68 may be secured in theframe by a friction or interference fit or may be secured by a fastener(not illustrated) to the frame and can be transversely moved. In oneembodiment, the bracket C is located approximately 1⅝ inches below theend plate 68.

The upper portion of the frame is traversed by a slot 69 which receivesa metal stabilizer plate 70. The stabilizer plate is secured in place bya threaded adjustment knob 72. The knob 72 connects with a threaded rod74. The rod extends through an opening in the plate 70 and threads intoa central threaded opening 75. The stabilizer plate 70 preferably has asquare configuration with four vertices which form edges 76. The edges76 are sharpened. When the plate 70 is mounted in position, one edge 76or vertex projects upwardly from the end surface 66 of the frame.Openings 78 are provided in the plate to provide a height adjustment forvaulted ceilings and other configurations. Alternatively, the projectingstructure is in the form of a barb.

The function of the stabilizer plate 70 is to provide a stabbing pointto engage into the wood proximate the interface of the top plate 22 andthe roof support member 26 to thereby stabilize the tool and preventmovement while the fastener is being torqued by the installation tool.The stabilization is especially important at the initial stages ofdriving the fastener.

In addition, the stabilizer plate functions to present a stabbing pointso that upon inspection, an inspector will readily perceive that thefastener is at the proper angle.

The guide assembly 50 is positioned by the installer at the intersectionof the top plate 22 and the roof support member 26 with the projectingstabilizer plate edge 76 engaging into the wood and the engagementsurface 62 engaging in surface-to-surface relationship against thevertical side of the top plate 22. The end surface 66 is typicallypositioned proximate the underside of the roof support member 26, but isslightly offset due to the less than complete penetration of thestabilizer edge, and the alignment bracket 68 engages the lower edgeportion of the top plate 22.

Prior to engagement of the guide assembly with the top plate/roofsupport structure (as previously described), a fastener 12 is droppedinto the fastener channel 52 with the fastener head 14 proximate to orengaging with the complementary coupler 43. A portion of the fastener 12is typically initially received in a chamber of tube 34 adjacent thedistal end 36. The fastener drill tip 16 is proximate the channelopening 53 in the engagement plate 62. It will be appreciated that theguide assembly 50 as properly positioned provides the proper entry pointand entry angle for the fastener 12 as the fastener is driven throughthe top plate 22 into the roof support member 26.

With reference to FIGS. 42 and 43, alternative embodiments of the guideassembly that mount to the end of the telescopic tube assembly of aninstallation tool are generally designated as guide head 150A and guidehead 150B, respectively. These guide heads include additional featuresboth for providing the proper alignment and positioning for the screwand for enhancing the ability of the operator and/or an inspector toverify that a proper connection has been made. Each of the guide headshas a frame 160 with a planar locating surface 162 disposed at an acuteangle with respect to a tube assembly. Locating surface 162 defines achannel opening for the fastener channel access of the tube assembly. Aplanar end plate 166 is configured to engage or closely approach theunderside of the roof support member 26.

An L-shaped bracket preferably extends transversely at opposed sides ofthe engagement surface and projects outwardly from the surface toprovide an alignment bracket 168 to engage the vertical support 24.Bracket 168 may be adjustable. A pair of arms 180 and 182 are pivotallymounted at the top of the frame. One or more of the arms 180 and 182 maybe pivoted upwardly to engage a vertical side of member 26 and provide aproper positioning relative to the roof support member 26.

A stabber point 170 projects through the end plate 166. In addition, theupper portion of the frame mounts a linear ink pad 190. In theembodiment position illustrated in FIGS. 42 and 43, the guide heads 160Aand 160B have not been positioned against the roof support member 26.Upon proper positioning, the pivotal arms 180 and 182 would engageagainst the sides of the support member 26, and the ink pad would make alinear mark indicated at 191 on the bottom of the roof support member26. In addition, the stabber 170 would stab into the wood and leave amark 171 as indicated. It should be appreciated that either the ink mark191 or the stab mark 171 could be used to identify both the properfastener as well as the proper entry angle of the fastener andaccordingly indicate that a proper connection has been completed.

The guide head 150B illustrated in FIG. 43 has a pair of barbs 176projecting from the end plate 166. When properly engaged under the roofsupport member 26, the pair of barbs would provide two marks 177 whichwould again provide a unique marking for indicating the properconnection. Of course, the barbs 176 also enhance the stability of theinstallation tool and the fastener during the installation process.

The installation tool preferably includes an auxiliary handle (inaddition to the handle on the driver 40) to facilitate two-handedpositioning and stability during the driving process. Various auxiliaryhandle configurations can be employed.

With reference to FIGS. 2 and 9, an auxiliary handle 80 is slidablymounted to the tube and is longitudinally adjustable to provide anauxiliary handle for the installer. The handle 80 includes a rear grip82 which radially projects radially or quasi-radially relative to thelongitudinal axis of the tube assembly. A forward rod 84 extends fromthe grip generally parallel to the tube assembly. The rod 84 connects toa forward yoke 86 which envelopes the outer surface of the tube assemblyand is slidable along the tube assembly. The intermediate portion of therod is received in a cam lock 88 carried by the fixed proximal tube 32that mounts to the forward portion of the driver 42. The rod locks inplace with the cam lock 88.

The tube 34 telescopes with the proximal tube 32 and is slidablyreceivable throughout the driving of the fastener 12 in the installationprocess as the fastener is driven to complete the connection. Thechanging dynamic relationships of the fastener 12, the guide assembly50, the telescopic tube assembly 30 and the handle 80 at the variousstages of installation are illustrated in FIG. 9.

The auxiliary handle 80 is selectively adjustable by the installer toprovide maximum stability and comfort to the installer. The handle locksin place with a pin 85. The handle 80 is initially adjustable. A button87 is pressed to release the telescoping tube 34 from its fixedrelationship with the proximal tube 32 and drive the threaded fastener.The handle 80 essentially remains stationary as the driver moves duringthe installation progress, as best illustrated in FIG. 9. The tube 32retracts relative to tube 34 to accommodate the progressive expelling ofthe fastener 12 from the fastener chamber 52. The telescoping tubes 32and 34 only lock when in the fully driven position, at which point, thefastener 12 is fully driven.

It should be appreciated that approximately six-inch driving link isrequired for driving a six-inch fastener.

With reference to FIGS. 10, 11 and 12A-C, an automatic locking handle isgenerally designated by the numeral 90. The handle 90 is generallyconfigured to radially extend from the proximal tube 32 and slide alongthe tube 32 during the driving process until it automatically locks atthe full drive position. The handle has an orthogonally projecting grip92 which connects with a yoke 94. The yoke 94 wraps around the tube 32and is exteriorly slidable therealong.

The automatic locking handle 90 is automatically locked by the use ofballs 96 which are entrapped in a bearing 98. The driving rod 49 has avarying diameter along a longitudinal portion. As best illustrated inthe sequence of FIGS. 12A-C, as the fastener 12 is driven, the geometryof the driving rod has reduced diametric surfaces allowing the balls toslip by and the outer distal tube 34 to fully telescope. The externalhandle can be placed anywhere along the proximal tube 32. It will beappreciated that as the fastener 12 is driven, the handle is rearwardlydisplaced toward the driver 42 until a fully locked position is obtainedand the telescoping tube 34 is retracted.

With reference to FIGS. 13, 14 and 15A-D, another handle which may beemployed for a third embodiment of a fastener installation tool isgenerally designated by the numeral 110. The handle 110 includes acircumferential grip 112 which extends around the proximal tube 132. Thegrip 112 may be easily moved along the base tube 32 and tightened inposition or loosened by means of a twisting motion on the grip about thelongitudinal axis of the tube assembly 30.

A protrusion 114 rides within an internal slot 116 which is attached infixed relationship to the driver 42. The proximal tube 132 forms theinternal slot 116, and the sliding tube 134 includes an external rib147. The internal slot 116 is not aligned with the rib 147 in thedormant/non-drive state (FIG. 15A). As the driver starts to drive, theprotrusion 114 starts to ride in the internal slot 116 until it changesgeometry and twists, thereby causing the handle to twist (FIGS. 15B-C).The foregoing continues until the second slot is aligned with theexternal rib, thereby allowing the tube 134 to fully telescope inwardly(FIG. 15D). When the installer feels the handle 110 rotate slightly, theinstaller knows that the fastener 12 has been sufficiently initiallydriven, and the installer can release the grip 112 on the handle andplace both hands on the driver 42.

Naturally, other handles are possible. In some embodiments, an auxiliaryhandle as such is not required. In such embodiments, the installermerely grips along the tube assembly at a location that appears to bemost advantageous.

The installation tool 10 is preferably battery powered and includes achargeable battery power pack. However, in some embodiments, the powerdriver (not illustrated) may be directly electrically powered andinclude a cord which connects with the power line.

With reference to FIGS. 16A and 16B, two different structural heights ofthe top plane 22 and two appropriately dimensioned installation toolsfor relatively tall and short installers (shown in silhouette) areillustrated, it should be appreciated that the dimensioning of thetelescopic tube assembly 30, in terms of longitudinal length, isestablished to accommodate the preferred application in connection withconnecting a top plate 22 to a roof support member 26 without theinstaller needing a ladder or a platform to obtain the correct reach fordriving the fastener. In addition, because the height and reach of aninstaller may significantly vary, the length of the telescopic tubeassembly 30 is preferably selected to accommodate a wide range ofinstallers' physical dimensions.

For applications wherein a fastener greater than 6 inches or even lessthan 6 inches may be applicable, an alternative guide assembly may beemployed. For such a guide assembly, the effective depth of the fastenerchannel is altered. In addition, the telescopic extremes of thetelescopic tubes 32 and 34 are adjusted to accommodate for the drivinglength for the fastener. Naturally, the coupler of the installation toolis adapted to complement the head of the fastener.

It should also be appreciated that for applications in which an angleother than 22½° is desired, the guide assembly may also be configured sothat the fastener channel is at an acute angle relative to theengagement surface at the prescribed optimum angle. Naturally, theposition of the alignment bracket 68 may also be varied in accordancewith a specific project. Multiple guide assemblies for variousinstallation angles may be provided and attached to the telescopic tubeassembly as desired.

For some embodiments, the power driver 40 is easily dismounted from thetelescopic tube assembly 30. The telescopic tube assembly may employ areceiver configured to receive and functionally attach to a wide rangeof dismountable drill guns without the torque driver being fullyintegrated with the telescopic tube assembly.

With reference to FIGS. 17-25, another embodiment of an installationtool (which does not show the power driver assembly) is generallydesignated by the numeral 200 (FIG. 17). Installation tool 200 includesa receiver 202 for the power driver assembly (not illustrated), atelescopic tube assembly 230 comprising telescopic tubes 232 and 234,and a fastener guide head assembly 250 which is mounted at the end 236of tube 234.

A handle assembly 210 is disposed in longitudinally fixed relationshipto tube 234 and includes a trigger 212 which is depressible into one ofessentially two positions. One partially depressed position of thetrigger 212 allows for the handle assembly to be angularly adjustedabout the longitudinal axis of the distal tube 234 at a preset definedangular position. The full depressed position of the trigger 212 allowsfor the proximal tube 232 to be retracted relative to the distal tube234 when the fastener 12 is driven. The handle assembly 210 alsoprovides for two-handed support of the tool so that the stabilizing edge276 can be effectively stabbed into the support member. It should beappreciated that the tubes 232 and 234 do not rotate relative to eachother with the non-rotatable position being ensured by a longitudinalflat 236 which engages through the handle assembly.

With reference to FIGS. 19A-B and 23-25, the handle 210 has a gripportion 214 which carries the trigger 212. The handle assembly 210 isattached to the distal tube 234 by a yoke 240 which is longitudinallyfixed between a pair of collars 241 and 243. The trigger 212 moves aramp 216 which engages complementary ramp 218 of a plunger 220. Theplunger 220 has a radially acting detent 222 which is biased inwardlyinto the tube 234.

A plurality of (preferably five) recesses 225 are angularly spaced infixed relationship to the outer tube 234. The projectable detent 222 islongitudinally aligned with the recesses 225 and receivable in aselected recess for retention under the plunger bias. Upon depressingthe trigger 212, the detent 222 is retracted from a recess 225.Angularly rotating the grip 214 relative to the distal tube 234 allowsdetent 222 to be angularly engageable into a selected recess 225 to fixthe angular position of the handle assembly 210 as desired by theinstaller. That angular position is further secured by a thumb screw 246at the top which is tightened to secure the desired angular position.

A pair of internal collar mounts 245 and 247 are respectively fixedlymounted interiorly of the tubes 232 and 234. The mounts allow rotationaland axial movement of the drive train. A spring 248 bears against themounts and essentially biases the tubes 232 and 234 to a maximumextended position which is limited by a stop 249. The spring 248 may beoptional. Stop 249 allows for replacement of the driver bit 282 tocomplement the fastener head. The plunger detent 222 also extendsthrough an opening 223 to prevent movement between the distal tube 234and the proximal tube 232 and thus fix the effective tool length. Whenthe trigger 212 is fully depressed, the plunger is retracted from theopening 223 to allow the proximal tube to move relative to the distaltube against the bias of the spring 248 until the fastener is fullydriven.

With additional reference to FIGS. 5, 17 and 20-22, a dual floatingalignment bushing or receiver guide 280 is mounted at the interior ofthe distal tube 234 and has a central opening which receives the outputcoupler 284 of the drive train 282. The guide 280 ensures a concentricalignment between the fastener and the driver. The dual receiver guide280 has a double conical or funnel-like constriction 286 which receivesthe head 14 of the fastener 12 and centers it for engagement by thecoupler 284 as illustrated.

A fastener guide head assembly 250 is mounted at the distal tip 236 ofthe tube assembly. The guide head assembly 250 has a generallycylindrical base 251 which is retained to the distal tube 234 by meansof one or more set screws 239 (FIG. 17). A sleeve 252 extends throughthe base 251 to form a channel which receives and guides the fastener12. Surface 262 defines the sleeve input opening 253 to sleeve 252 forthe fastener as correspondingly described with respect to guide assembly50. The sleeve 252 receives the fastener so that the head 14 is properlypositioned to be readily engageable by the torque coupler 282. The majorthread diameters of the fastener 12 and the interior diameter of thesleeve 252 are configured so that the interior diameter of the sleeve isonly slightly larger than the major thread diameters of the fastener.Preferably, the maximum diameter of the head 14 is approximately equalto the major diameter of the threads. It will be appreciated that as thefastener 12 is loaded into the guide head assembly 250, the head 14moves through the sleeve or channel 252 and is convergently directed viathe funnel-like constriction 286 (FIG. 20) toward engagement with thetorque coupler 284 of the drive train. The coupler 284 is also axiallycentered by the dual receiver guide 280. The dual receiver guide 280 canaxially move or float within the tube. The movement is inwardly limitedby a dimple 281.

The guide head assembly 250 is preferably a cast or molded member oflightweight rigid form which includes a frame extending from the basewith a planar engagement surface 262 disposed at an acute angle withrespect to the lower planar mounting surface 264. Mounting surface 264preferably engages against the end of the tube assembly and transverselyextends across the distal end 236 of the tube 234. A planar end plate266 is parallel to surface 264 and positioned to engage the underside ofthe roof support member 26. The acute angle is preferably 22½°, althoughother angles may be provided depending on the intended application ofthe installation tool. The specific angle can be provided with a guidehead assembly having the required angle of the sleeve or guide channelrelative to the engagement surface 262.

A transverse slot 265 receives an L-shaped alignment bracket 268 whichprotrudes transversely at opposed sides of the engagement surface 262and also projects outwardly from the surface 262. A set screw 271secures the bracket 268 and allows the bracket 268 to be adjustedlaterally, for example, when required at corners. The alignment bracket268 is positioned and configured to fit below the 2×4 at the top plate22 to ensure proper perpendicular alignment with the top plate. Forcorner configurations, the alignment bracket 268 may be moved to anextreme lateral position, either left or right of the position as shownin FIG. 21.

The upper portion of the frame is traversed by a slot 269 which receivesa metal stabilizer plate 270. The stabilizer plate is secured by anadjustment knob 272 which connects with a threaded rod 274. The rodextends through an opening in the plate and threads into separatethreaded opening 275. The stabilizer plate 270 preferably has a squareconfiguration with four vertices which form edges 276. The edges 276 aresharpened. When the guide head assembly 250 is properly positioned asharp edge 276 projects upwardly from the edge surface 266 of the frame.The function of the stabilizer plate 270 with edge 276 is to provide astabbing structure to engage into the wood proximate the interface ofthe top plate 22 and the roof support member 26 to thereby stabilize thetool 200 and prevent movement or walking while the fastener 12 is beingtorqued by the installation tool. The stabilization is important at theinitial stages of driving the fastener.

FIGS. 26-29 illustrate installation tools 300, 400, 500 and 600 whichincorporate various adapters for coupling with the conventional rotarydriver tools.

FIG. 26 illustrates an installation tool 300 with an adapter 302 forattachment to the type of rotary driver tool which includes a collarmounted auxiliary handle. Such handles are frequently found on hammertype drills to provide additional leverage for the user. In this case,the disclosed adapter 302 replaces the auxiliary handle of the drivertool 340 with a collar attachment to secure the adapter to the rotarydriver behind the chuck. The chuck is used to secure the extended lengthdrive shaft to the rotary driver and a grip 310 permits the user tosecurely grasp and maneuver the tool 300 and adapter 302. The grip 310of the tube assembly 330 receives a manually fed plunger front portion.The plunger front portion is configured to telescope inside the grip ofthe adapter during screw installation. The manual feed plungerincorporates a screw guide 353 which surrounds and guides the screwduring installation. The guide head 350 is configured to permit the userto accurately place the screw in the center of a wood structural memberso that the screw will be installed centered on the truss and parallelto truss orientation, and preferably at a 22.5° angle with respect to avertical direction. This 22.5° angle is selected to ensure that theinstalled screw passes through the lower building components andaccurately penetrates an upper building component, for example a rooftruss. It will be apparent to those skilled in the art that other anglesmay be suitable for other applications and that alternative plunger tipconfigurations will be desirable for other screw installations.

The rotary tool adapter illustrated in FIG. 26 includes a cylindricalscrew magazine 390 disposed about the grip 310 of the tube assembly 330.In this embodiment, screws 392 are removed from the magazine 390 andmanually inserted into the screw guide 353 located in the plunger frontend of the tube assembly 330. The screw guide is configured to closelyreceive a screw without excess radial space around the screw. The screwguide is configured to accurately start and deliver the screw 392through the wood structural members. The length of the screw and theintended structural purpose of the installation require precise guidanceand delivery of the screw through the associated wood members.

FIG. 27 illustrates an installation tool 400 with a second embodiment ofa tool adapter for use with the disclosed construction system. Theembodiment of FIG. 27 illustrates a pistol grip adapter 402 configuredto engage a rotary driver tool 440. The pistol grip permits the user tomaintain control over the adapter and rotary tool during screwinstallation. This embodiment also includes a grip 412 forward of thepistol grip 410 and a plunger/screw guide 453 at the forward end of thetube assembly 430. The tip of the plunger/screw guide is configured toassist the operator to drive screws at the 22.5° angle (FIG. 27, lowerright), though other tip configurations and angles are compatible withthe disclosed construction system. The embodiment of FIG. 27 shows anarrangement where the position of the pistol grip 410 is adjustable onthe rear portion of the tube assembly 430. This arrangement permits theuser to customize the ergonomics of the adapter to the task and anoperator. A lever actuated cam lock system 414 allows the user todisengage the pistol grip 410 from a tubular rear portion and to fix thepistol grip in a selected alternative position. FIG. 27 illustrates aview of a guide head 450 for the screw guide plunger which includes asight line enhancing an operator's ability to center the screw on astructural member during installation.

FIGS. 28A and 28B illustrate an installation tool 500 with analternative embodiment of a tool adapter 502. The embodiment of FIGS.28A and 28B includes a pair of flexible arms 504 configured toelastically deform and grip the sides of a rotary driver tool 540.Thermoplastic resin pads 506 enhance frictional engagement between thearms and the sides of the rotary tool. The adapter 502 of FIGS. 28A and28B also includes an extended grip area 510 for use by the operator. Thescrew guide/plunger front end of the adapter is shown with one ofseveral contemplated plastic guide heads 550. The illustrated head 550is configured to aid the operator in installing a screw at a 22.5° anglerelative to the vertical as previously described. A plurality of plastictips for mounting on the end of the screw guide can be swapped out fordifferent screw installation purposes.

In installation tool 600 with a further alternative tool adapter 602 isdisclosed in FIG. 29. In this embodiment, the adapter is secured to therotary tool by a ratchet type strap 604 extending from the sides of theadapter around a rear portion of the rotary tool 640. This configurationpermits the adapter to be securely integrated with the rotary tool.Various means may be provided to tighten the ratchet strap in a mannersimilar to arrangements used on snow sport bindings for example. In theembodiment of FIG. 29, the rear grip portion 610 has an ergonomic shapeand a textured grip area to enhance operator ease of use and safety. Theembodiment of FIG. 29 shows a molded plastic plunger guide head 650 withan integrated molded 6″ screw clip 690. The grip portion 610 isconfigured to permit the forward plunger portion to recede into the gripportion during screw delivery. A pump action screw feeder is illustratedwhere screws are moved from a clip to a screw guide by manual cycling ofthe manual pump grip 695. Once the first screw is manually fed into thescrew guide, further screws may be delivered with the longitudinalcycling of the screw guide during subsequent screw installation. A sightline 691 on top of a clip 690 enhances the user's ability to center thescrew guide on a structural member for accurate delivery of screws.

Accessories can also aid in efficient use of the disclosed installationtools and the construction system. Various ways of maintaining a supplyof fasteners on the person of an operator are disclosed. Suchaccessories minimize the necessity to interrupt installation to renew asupply of fasteners. For example, FIG. 30 illustrates a belt holster 700holding several screws from which the operator efficiently retrieves ascrew and manually installs each screw in a screw guide.

FIGS. 31A-31B and 32A-32B respectively illustrate a bandolier 700A andleg mounted screw holster 700B as alternatives for maintaining a numberof screws 702 on the person of the operator. The screw holding systemsillustrated in FIGS. 31A-31B and 32A-32B may include magnets arranged tomaintain screws in the disclosed holders while the worker is movingabout the construction site. This reduces the chance that screws mayfall out of the disclosed holders and enhance ease of use. The fastenerholders of FIGS. 30-32B may include tapered plastic tubes 704 for eachfastener. The tubes can be configured to cover the sharp points of thefasteners to avoid inadvertent injury to the operator. For example, thebottom end of the tapered tubes 704 may be closed.

The disclosed installation tools may be adapted for use in driving awide range of fasteners to implement various connections of woodcomponents in a wood structure. A preferred fastener 900 which hasparticular applicability for providing a connection between a top plateand a truss frame is illustrated in FIG. 33. Fastener 900 is a six-inchfastener which has an uninterrupted thread 910 extending from a gimletpoint 912 toward a head 914. The thread 910 is approximately fiveinches. In one embodiment, the gimlet point has a 30° angle. The head914 has a socket which may be a T25 Autosert drive or other socketconfiguration with a fixed diameter that preferably ranges from 0.260 to0.290 inches, which is approximately the major diameter of the thread910.

Depending upon the application, a number of other fasteners are possibledepending upon the connection to be implemented as well as the specificstructural components.

FIGS. 34A-34D illustrate representative fasteners compatible with thedisclosed construction system. The disclosed fasteners 920A and 920B aredouble-threaded, having a self-drilling tip 922 and approximately 2″bottom thread 924 paired with a threadless center shank portion 926 and1½″-2″ top thread. The top thread 928 (under the head 930A and 930B) isfor increasing head pull-through performance. The top thread 928 in oneconfiguration has a higher pitch, e.g., a greater number of threads perinch, to reduce the rate of penetration of the fastener as the topthread enters the wood during installation. This configuration willreduce the likelihood of board jacking and enhance clamping duringinstallation. The top thread 928 may be of the same major and minordiameter as the bottom thread or may have a larger major and/or minordiameter to enhance pull-through resistance. The axial length of the topthread 928 may be as short as ½″ depending upon the configuration of theupper thread and the desired pull-through resistance. The threadlesscenter portion of the screw is arranged to permit maximum penetration ofthe bottom thread 924 into the various structural members prior toengagement of the top thread. The screws are illustrated with a Torxtype drive socket 932 configured to facilitate automated or mechanizedscrew installation in the disclosed screw guides.

Different bright colors or tints are applied to the screws 920A and 920Bto readily identify the fastener for both proper connection andinspection purposes. Currently, building inspectors can easily identifymetal brackets applied to structural members. The alternative use ofthreaded fasteners potentially makes inspections more problematic.Threaded fasteners are not as easily seen by building inspectors. Evenif the inspector can see the ends of the fasteners, the inspector wouldnot necessarily know what type of fastener is installed. The disclosedconstruction system addresses this issue by applying bright colors tothe fastener or at least the head of each fastener. Brightly coloredfastener heads 930A and 930B provide a clear visual indication of thetype of fastener installed in a given location. Bright colors can alsohelp builders and workers to identify the correct fastener for aparticular purpose.

FIGS. 35A-35E illustrate an embodiment of the representativeinstallation tool and construction system being used to install thedisclosed threaded fasteners to connect various structural components.Note that the construction worker standing on the floor has clear sightlines to the installed fasteners whether the installation is overhead orat floor level. The worker is neither climbing a ladder nor squattingdown at floor level. The disclosed construction system should enhanceworkers' safety and productivity while reducing the possibility ofinjury or worker discomfort.

FIGS. 36A-36C illustrate a proposed embodiment of a fastener 940compatible with the disclosed construction system. A Torx™ drive socket942 in the screw head 944 is shown but other socket-type drive heads,such as square drive, Torx T-Tap™, Torx Plus™, Phillips, etc. arepossible. The head 944 of the fastener employs an internal (socket) typedrive, is compact and relatively small in diameter to reduce thelikelihood of interference with other building components such assheathing on the outside and sheetrock on the inside of a structure. Therelatively small head can reduce the fastener resistance to pullingthrough wood structural members when subjected to forces along the axisof the fastener.

In the disclosed fastener 940 shown in FIGS. 36A-36C, it can be seenthat the top thread 946 has a higher pitch than the bottom thread 948.This thread pitch differential between top and bottom threads for someapplications to reduces board jacking and enhances building componentclamping during installation of the disclosed screws. The top threads ofthe disclosed fasteners are configured to enhance pull-throughresistance of the disclosed fasteners. It will be noted that the majordiameter of the top thread 946 is larger than the major diameter of thebottom thread 948. The disclosed fastener employs a single diametershank which is formed to result in the disclosed thread patterns.Multi-diameter blanks are also contemplated where the diameter of theshank at the top of the fastener may be larger to provide more materialfor the top thread resulting in enhanced pull-through resistance. Thedisclosed threaded fasteners are contemplated between 5.25″-6″ in lengthbut length will vary depending on the intended purpose of the fastener.The illustrated fastener 940 has a 2″ bottom thread 948 and a 1.75″ topthread 946. The length of the top thread and the length of theunthreaded center portion of the screw shank can be varied to tune screwperformance.

While the fastener 940 employs a thread configuration where the topthread 946 has a higher thread count (TPI) than the bottom thread 948,fasteners with the same thread count or a bottom thread having a higherthread count than the top thread may be useful for some purposes.

FIGS. 37A-37C illustrate an alternative screw configuration 960contemplated as useful for certain locations in a structure. Thisfastener is a single thread fastener with a fin 962 or wing type boringfeature adjacent to the tip. Fastener 960 may be suitable for a bottomplate to rim joist applications for example. The flared head 964 of thisfastener provides enhanced pull-through resistance in locations whereinterference with sheathing or sheetrock is not a concern. The boringfeature reduces the possibility of cracking the wood structural memberduring screw installation. This fastener has a large diameter mainthread 966 to reduce strip out of the fastener when tightening multipleplies of laminated veneer lumber beams together. Alternatively, theboring feature may be configured as more of a fin type wing that canappear as a spiral and may be applied by a threading machine,eliminating the need for a secondary pointing operation. There may betwo, three or four fins 962 that are equi-angularly distributed aboutthe circumference of the screw tip. Each of the fasteners illustrated inFIGS. 36A-36C and 37A-37C are configured so that the head penetratesslightly into a structural member or sits flat against the member toprevent interference with other building components such as sheathing orbrackets, straps and joist hangers that may need to be installed.

FIGS. 38A-38C illustrate various metal brackets and straps that may beemployed in conjunction with the disclosed construction system. FIGS.38A-38C illustrates the junction of a roof truss with the top plate of astructure. This is a location where many building codes require that thetruss be strapped or tied to the top plate using a hurricane tie or thelike. Metal plates 802 are typically used to hold truss componentstogether. Such truss plates 802 are installed in a factory setting andinclude perforations that provide metal penetrating barbs to hold theplate to the truss components, thereby securing the truss components toeach other. The resulting perforated configuration may provide anopportunity to attach L-shaped brackets 804 to tie the roof truss to thetop plate of the wall as shown in FIGS. 38A-38C. Screws or bolts 806 maypass through the roof truss plates 802 and L-shaped brackets 804.Threaded fasteners 808 may be used to attach the lower portion of theL-shaped bracket to the top plate. FIG. 38C illustrates an L-shapedbracket 804 with perforations and wood penetrating barbs arranged tomatch the perforations in the truss plates. The L-shaped bracket 804could be installed by pressing or hammering into the truss plates andthreaded fasteners 808 can be employed to tie the L-shaped bracket 804to the top plate.

FIGS. 39A-39E illustrate a possible alternative configuration for atruss plate. The disclosed truss plate 810 is U-shaped with the verticalportions of the U including perforations and wood penetrating pointsconfigured to secure the truss plate to the truss components. The bottomportion of the U-shape includes wood penetrating barbs 812 directed awayfrom the truss and intended to penetrate the top plate of the wall.Threaded fasteners 814 contemplated in the disclosed construction systemare then installed to tie the truss to the top plate and wall. Thedownward extending barbs 812 from the proposed U-shaped truss plate gripthe top plate and enhance a secure connection of the truss to the wall.Further, the metal bottom panel 818 of the proposed truss plate 810enhances pull-through resistance of the fastener relative to the truss.

FIGS. 40A-40B illustrate an alternative metal construction bracketsystem. Flexible metal brackets 820 are arranged in elongated stripswith score marks 822 or indentations between the segments. The elongatedstrips may be cut or broken between segments to provide metal bracketsof different length. FIG. 40A illustrates a five-segment bracket placedto tie a vertical stud to a top plate and a roof truss. The disclosedmetal brackets 820 include metal perforations which can be pressed intothe wood to provide a secure bracket to wood connection.

FIGS. 41A-41D illustrate a tool 830 complementary to the disclosedflexible metal brackets 820. The tool 830 is configured to bend andclamp the proposed bracket in place, pushing the perforated metal barbsinto the wood. A tool adapter 832 provides clamping force on thedisclosed brackets. A rotary drive tool adapter is disclosed, though ahydraulic tool is also suitable for this purpose. The jaws of the toolinclude protrusions configured to mate with perforations on the bracketsand push portions of the brackets into the wood, thereby attaching thebrackets to the wood.

FIGS. 44A-F illustrate a fastener 1000 which can be employed in aninstallation tool as previously disclosed and which is compatible withthe previously disclosed construction system. The fastener 1000 has acompact, proximal drive head 1010 which inwardly uniformly tapers at asmall acute angle from a maximum diameter at the proximal engagement end1012 to a slightly smaller diameter adjacent a fastener neck portion1014. For a preferred embodiment, the acute angle is approximately 4°.The head 1010 has a recess or socket 1016 which is adapted for rotatabledrive engagement by the drive coupler of the installation tool. In apreferred form, the socket 1016 is configured to couple with a T-25AutoSert™ drive and preferably has a penetration depth P of between0.065 and 0.075 inches (FIG. 44E). Other socket-type drive headconfigurations compatible with a rotatable drive engagement, such asTorx T-Tap™, Torx Plus™, Phillips, square drive socket, etc. arepossible. The maximum diameter of the head 1010 is preferably 0.260inches and the head axially extends approximately 0.200 inches.

A shank 1020 integrally extends from the head neck/end portion 1014 to atapered distal tip 1030. The shank has an unthreaded portion 1022adjacent the head of uniform diameter. An uninterrupted threaded portion1024 along most of the shank is generally uniformly helically threadedalong the remainder of the shank and onto the tip.

The thread 1040 preferably has a pitch of 7.5 threads per inch and asymmetric thread flank angle α having a range of 25° to 45° (FIG. 44F).In one preferred embodiment, angle α=40°. The major diameter of thread1040 is approximately 0.260 inches which is the maximum diameter of thehead 1010. It should be noted that the corresponding fastener channel52, 252 in a corresponding installation tool would be approximately0.030 inches.

In one preferred embodiment, the minor diameter of thread 1040 is 0.172inches; the diameter of the unthreaded portion 1022 is approximately0.188 inches; the length of fastener 1000 is approximately 6.00 inches;and the length of thread 1040 is approximately 5.00 inches. The thread1040 preferably continues onto the tapered tip 1030. Naturally, otherfastener lengths, head and thread configurations are possible.

While the preferred embodiments of the foregoing installation toolfasteners and construction system have been set for purposes ofillustration, the foregoing description should not be deemed alimitation of the inventions herein. Accordingly, various modifications,adaptations and alternatives may occur to one skilled in the art withoutdeparting from the spirit and the scope of the present invention.

The invention claimed is:
 1. A fastener for an installation toolcomprising: a head portion defining a recess for coupling with a drivingtool and having a maximum head diameter; an elongated shanklongitudinally extending from said head portion and terminating in atapered tip; and a helical thread longitudinally extending along saidshank and having a minor diameter and a major diameter substantiallyequal to said maximum head diameter, wherein said fastener has a lengthand the length is greater than 15 times the maximum head diameter andthe major diameter is no greater than 1.75 times the minor diameter. 2.The installation tool fastener of claim 1 wherein said fastener has alongitudinal length of approximately 6.00 inches.
 3. The installationtool fastener of claim 1 wherein said helical thread has a pitch of 7.5threads per inch.
 4. The installation tool fastener of claim 1 whereinsaid helical thread extends onto said tapered tip.
 5. The installationtool fastener of claim 1 wherein said major diameter and said maximumhead diameter are each approximately 0.26 inches.
 6. The installationtool fastener of claim 1 wherein said shank has an unthreaded portionadjacent said head.
 7. The installation tool fastener of claim 6 whereinsaid helical thread extends approximately 5.00 inches.
 8. Theinstallation tool fastener of claim 1 wherein said head portion has aslight taper of approximately 4° from a maximum diameter portionadjacent an engagement end.
 9. The installation tool fastener of claim 1wherein said recess is selected from a group consisting of a socket witha plurality of radial portions, a Philips socket and a square socket.10. The installation tool fastener of claim 1 wherein said threadedportion has a length greater than 10 times the major diameter.
 11. Afastener for an installation tool comprising: a head portion defining arecess for coupling with a driving tool and having a first coupling endwith a maximum head diameter and uniformly tapering toward a second endat an acute angle; an elongated shank longitudinally extending from saidhead portion and terminating in a tapered tip and having a threadedportion and an unthreaded portion adjacent said second end; and a threadlongitudinally extending along said shank onto said tapered tip andhaving a major diameter substantially equal to said maximum headdiameter and said thread having a minor diameter along said shank,wherein the fastener has a length and the length is greater than 15times said maximum head diameter and the major diameter is no greaterthan 1.75 times the minor diameter.
 12. The installation tool fastenerof claim 11 wherein said fastener has a longitudinal length ofapproximately 6 inches and said thread extends approximately 5 inches.13. The installation tool fastener of claim 11 wherein said helicalthread has a pitch of 7.5 threads per inch.
 14. The installation toolfastener of claim 11 wherein said major diameter and said maximum headdiameter are each approximately 0.26 inches.
 15. The installation toolfastener of claim 11 wherein said acute angle is approximately 4°. 16.The installation tool fastener of claim 11 wherein said recess isselected from a group consisting of a socket with a plurality of radialportions, a Philips socket and a square socket.
 17. The installationtool fastener of claim 11 wherein said threaded portion has a lengthgreater than 10 times the major diameter.